Key cast concrete construction system

ABSTRACT

A system for precasting concrete panels of a uniform modular dimension and erection of the same using a tapered keyslot and forming system so to speed production on single and multistory buildings.

United States Patent [72] inventor Robert C. Amaun 3465 5011111 103111 St., c/o R. W. Industries, 1111,1911: Allis, Wis. S3214 \Zl] Appl. No. 652,779 [2 Filed July 12. 1967 [45] Patented Aug.10,l971

[54] KEY CAST CONCRETE CONSTRUCTION SYSTEM 2 Claims. 33 Drawing Figs.

[52] US. Cl. 249/35, 249/18, 249/99 {51] Int-Cl. E041; 15/1111 [50] Field 01 Search 249/18,20, 21, 26. 33, 34, 38. 39, 44, 4S, 47,9,150,155,l58, 160,163,165, 35,99,101

[56] Relentless Cited UNITED STATES PATENTS 1,029,674 6/1912 Dunagin 249/21 X 1,323,557 12/1919 Tourtelotte 249/44 1,444,588 2/1923 Copeland 249/21 X 1,579,822 4/1926 Knickerbocker 249/33 X Hayes Primary Examiner-J. Spencer Overholser Assistant Examiner Michael 0. Sutton Attorney-Andrus, Sceales, Starke 8L Sawal! ABSTRACT: A system for precasting concrete panels of a uniform modular dimension and erection of the same using a tapered keyslot and forming system so to speed production on single and multistory buildings.

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KEY CAST CONCRETE CONSTRUCTION SYSTEM This invention relates generally to construction systems. More specifically it relates to a concrete construction system.

A principal object of the present invention is to provide a key cast concrete construction system which will simplify and speed up the erection of buildings utilizing concrete construction without costly in-place forming of concrete as is conventionally being done at the present time.

Another object of the present invention is to provide a key cast concrete construction system which will allow precasting of panels for a building in a central location or precasting of panels on site by transporting forms for such to the site.

Yet a further object of the present invention is to provide a key cast concrete construction system wherein a tapered keyslot for receiving the key cast panels being formed in the foundation, and the lintels for the subsequent floors would allow the panels to be stood in place with a minimum amount of bracing required.

Still a further object of the present invention is to provide a key cast concrete construction system wherein the design of the form pieces both for the window and door panels would allow universal use of most of the pieces, thereby requiring the kept inventory to a minimum.

Yet a further object to the present invention is to provide a key cast concrete construction system wherein the design of the exterior lintel forms allow the form to be used for the perimeter of the foundation, thereby eliminating the need of two sets of forms.

Other objects of the present invention are to provide a key cast concrete construction system which is simple in design, inexpensive to manufacture, rugged in construction, ease to use and efficient in operation.

These and other objects will be readily evident upon a study of the following specification and the accompanying drawings wherein:

FIG. 1 is a perspective view of a building corner with the key cast panels standing and metal forms in place;

FIG. 2 is a top plan view of the key cast lintel form;

FIG. 3 is a front elevation view thereof;

FIG. 4 is an end elevation view thereof;

FIG. 5 is a top plan view of the key cast splice form;

FIG. 6 is a front elevation view thereof;

FIG. 7 is a side elevation view thereof;

FIG. 8 is a top plan view ofa key cast outside corner form;

FIG. 9 is a front elevation view thereof;

FIG. 10 is a side elevation view thereof;

FIG. 11 is a top plan view ofa key east end cap form;

FIG. 12 is a front elevation view thereof;

FIG. 13 is a side elevation view thereof;

FIG. 14 is a top plan view ofa key cast inside lintel form;

FIG. 15 is a front elevation view thereof;

FIG. 16 is a side elevation view thereof;

FIG. 17 is a top elevation view ofa key cast corner splice;

FIG. 18 is a front elevation view thereof;

FIG. 19 is a top elevation view of a door panel;

FIG. 20 is a front elevation view thereof;

FIG. 21 is a side elevation view thereof;

FIG. 22 is a front elevation view of a window panel;

FIG. 23 is a top elevation view of a key slot;

FIG. 24 is a front elevation view ofa key slot;

FIG. 25 is an edge view ofa key cast panel header form;

FIG. 26 is a side elevation view thereof;

FIG. 27 is a front elevation view showing the key cast door panel forms assembled prior to placing steel and pouring of the concrete;

FIG. 28 is a top plan view of a key cnsl panel outside edge form;

FIG. 29 is a side elevation view thereof;

FIG. 30 is an edge view thereof;

FIG. 31 is an end elevation view of a key cast panel foot piece;

FIG. 32 is a side elevation view thereof; and

FIG. 33 is an edge or top view thereof.

Referring now to the drawings in detail, the reference numeral 50 represents a key cast concrete construction system according to the present invention wherein there are a plurality of forms that are used for precasting of concrete panels which are to be of uniform modular dimension.

Thus as is shown in FIG. 1 of the drawing, a building 51 is shown fragmentarily having a window panel 52 forming adjacent walls to a corner 53. In the construction of the panels shown and the associate corner, a number of forms have been utilized.

A key cast outside form 54 is used as a lintel or footing form, the form 54 being shown in detail in FIGS. 2, 3 and 4. The form 54, as illustrated in FIGS. 2, 3 and 4, includes a pair of generally flat surfaces 92 and a central inwardly extending projection or surface deviation 93 which is defined by a pair of tapered-end surfaces 94, a taperedor inclined-bottom surface and an offset surface 96 which is generally parallel to surfaces 92. The end surfaces 94 diverge in a direction away from the surfaces 92 and also converge in a direction from the upper edge of the form 54 downwardly, thereby providing the surfaces 94 with a compound taper. The bottom surface 95 is inclined downwardly, as illustrated in FIG. 4, in a direction away from the surfaces 92. The lintel or footing form 54 is connected by a key cast spreader bar 55 to a key cast inner lintel form 56. The key cast inner lintel 57 is thus formed therebetween. At the corner 53 there is a key cast outsidecomer form 58 which is shown in greater detail in FIGS. 3, 9 and 10. The outside-comer form is of angle configuration when viewed from above and having wall sections 59 and 60 at right angles to each other.

One end of the outer lintel form 54 is mounted on the outer corner form, the opposite end of the outer lintel form being mounted upon a key cast panel-splice form 61, shown in greater detail in FIGS. 5, 6 and 7. The splice form 61 comprises a generally flat panel when viewed from above. The splice form 61 is positioned between panel 52 and another wall section 62 which may or may not include a window as is shown in FIG. I of the drawing. Should the wall of the building terminate, then an end cap form 63 shown in detail in FIGS. ll, 12 and 13 would he used to f irm .no end of the concrete construction. As is shown in FIG. ll of the drawing, the endcap form 63 is of U-shapcd configuration when viewed from above, the form having parallel, spaced-apart sidewalls 64 and 65 having an interconnecting wall 66 therebetween.

As is shown in FIG. 1 of the drawing, a key cast corner splice 67 forms the inner corner between the inner lintel forms 56, the corner splice 67 being shown in greater detail in FIGS. 17 and 18.

It is to be noted that the various forms are provided with bolt holes 68 so that the forms may be clamped or secured together by bolts. The outside lintel form 54 is additionally provided with spreader and stake holes 69 for purpose of receiving the key cast spreader bar 55. Additionally, snaptight openings 70 are provided in some of the forms as is shown in the splice form 61 and outside corner form 58.

The key cast door panel 71 illustrated in FIGS. 19, 20 and 21 is of generally inverted, U-shaped configuration having vertical, spaced-apart portions 72 and a horizontal connecting portion 73 each of which are provided with openings 74 for purpose of receiving reenforcing rods 75. As is shown in FIG. 20, a key cast slot 76 is formed in a second floor lintel so as to receive a key cast panel therewithin.

In FIG. 22, a key cast window panel 77 is shown having an opening 78 for the purpose of a window. This panel is likewise provided with the rods 75 us are shown in FIGS. i9, 20 and 2! of the door panel. It is of course understood that the window size may be varied and need not necessarily be as is shown in the drawing. It is to be noted that the key cast panels for a second-floor construction of a building are identical with a first-floor panels except that the key section has to be 8 inches longer so to reach the key slot cast in the first-floor lintel which bearing is provided for the 8 inch span crete deck.

In FIGS. 23 and 24 a keyslot is shown as indicated by the reference numeral 79. It will be noted, as shown in FIG. 24,

that the taper for both edges and bottom of the slot are shown.

In one particular design this taper may comprise a one-half inch difference between the upper and lower edges which are 6 inches apart.

A header form universal for all panels is shown in FIGS. 25 and 26 and identified with the reference numeral 80. it will be noted that one-quarter inch thick plates 81 are welded on the keytang at each end of the header form for the purpose of reenforccment. The header form is provided with slots 82 for receiving spreader bars 83 of U-shaped configuration. The tangs 84 ot' the header form are received within slots 85 of outside edge form 86. Openings $7 in the outside edge forms are for the purpose of receiving spreader bars 88, a foot form 89 is connected between the lower ends of the outside edge forms, as is shown in H6. 27 of the drawings.

A foot piece 90 shown in FIGS. 31, 32 and 33 is provided with tangs 91 at each end which may be of the same dimension as the tangs on the header form, the tangs 91 being likewise receivable within the outer edge forms 86.

it is to be noted that buildings designed for the use of the key cast system have a center utility core which allows the building site pad to be leveled, compacted, plumbing roughed in the slab and other utilities installed from a centerline which would be determined by an engineered stake-out, all prior to bringing the keycast forms upon the site. This again allows maximum use of the form system on other buildings prior to tying them up for a specific building, while waiting for mechanical trades to complete their own particular work.

This system of construction will speed up production on large apartment buildings by as much as 60 days per building. This is using a 24 apartment building for illustration purposes. Thereby saving construction costs as well as financial costs incurred while a building is under construction.

While various changes may be made in the detailed construction, it is understood that such changes will be within the spirit and scope of the present invention as is defined by the appended claims.

lclaim:

il. in a construction system, a form for casting a castable material, comprising a first wall, a second wall spaced from the first wall with the space between said walls adapted to receive a castable material, said first wall having an inwardly extending surface deviation provided with a compound taper composed of at least three tapered surfaces, said inward deviation defining a compound tapered slot in the mass of cast material adapted to receive a complementary compound tapered tang of a building panel, said surface deviation being defined by a series of wall sections including a pair of nonparallel-spaced endwall sections extending inwardly from said first wall toward said second wall and an offset wall section connecting said end wall section together and disposed substantially parallel to said first wall, and a tapered bottom wall section connecting the lower edges of said end wall sections,

said end walls diverging in a direction from the first wall to the second wall and said end walls converging in a direction from the upper edge of said wall downwardly, and said bottom wall being inclined downwardly in a direction from the first wall to the second wall.

2. The construction system of claim 1, wherein said form is a footing form and said castable material is concrete, said first wall being provided with a series of said surface deviations spaced along the length of said footing form. 

1. In a construction system, a form for casting a castable material, comprising a first wall, a second wall spaced from the first wall with the space between said walls adapted to receive a castable material, said first wall having an inwardly extending surface deviation provided with a compound taper composed of at least three tapered surfaces, said inward deviation defining a compound tapered slot In the mass of cast material adapted to receive a complementary compound tapered tang of a building panel, said surface deviation being defined by a series of wall sections including a pair of nonparallel-spaced endwall sections extending inwardly from said first wall toward said second wall and an offset wall section connecting said end wall section together and disposed substantially parallel to said first wall, and a tapered bottom wall section connecting the lower edges of said end wall sections, said end walls diverging in a direction from the first wall to the second wall and said end walls converging in a direction from the upper edge of said wall downwardly, and said bottom wall being inclined downwardly in a direction from the first wall to the second wall.
 2. The construction system of claim 1, wherein said form is a footing form and said castable material is concrete, said first wall being provided with a series of said surface deviations spaced along the length of said footing form. 